JP2012520163A - 内燃エンジン用耐老化性触媒物品 - Google Patents
内燃エンジン用耐老化性触媒物品 Download PDFInfo
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- JP2012520163A JP2012520163A JP2011551235A JP2011551235A JP2012520163A JP 2012520163 A JP2012520163 A JP 2012520163A JP 2011551235 A JP2011551235 A JP 2011551235A JP 2011551235 A JP2011551235 A JP 2011551235A JP 2012520163 A JP2012520163 A JP 2012520163A
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- 238000002485 combustion reaction Methods 0.000 title claims description 8
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- BASFCYQUMIYNBI-UHFFFAOYSA-N platinum Chemical compound [Pt] BASFCYQUMIYNBI-UHFFFAOYSA-N 0.000 claims abstract description 118
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Abstract
【選択図】なし
Description
本出願は、35 USC § 119(e)の下、2009年2月20日に出願された米国仮出願第61/154,053号に対する優先権の利益を主張し、当該出願は、参照により本明細書に組み込まれる。
1つまたは複数の実施形態に従って、基材は、通常、TWC触媒を調製するために使用される物質のうちのいずれかであってもよく、好ましくは金属またはセラミック構造を含む。任意の適切な基材、例えば、通路がそこを通る液流に対して開くように、基材の入口または出口面からそこを通って伸長する複数の微細な平行ガス流路を有する種類のモノリシック基材が用いられてもよい。それらの液体入口からそれらの液体出口まで本質的に直線路である通路は、通路を通って流れるガスが、触媒物質と接触するように、触媒物質が「ウォッシュコート」として被覆される壁によって画定される。モノリシック基材の流路は、台形、長方形、正方形、正弦波、六角形、楕円形、円形等の任意の適切な断面形状であり得る、薄壁チャネルである。そのような構造は、断面1平方インチ当り約60〜約600以上のガス入口の開口(すなわち、「セル」)を含み得る。
本発明の触媒物質は、2層で形成される。各触媒層の組成物は、PGM成分のスラリーとして調製され、このスラリーを使用して、基材上に層を形成する。物質は、先行技術においてよく知られている過程によって容易に調製することができる。代表的な過程は、以下で説明される。本明細書で使用される、用語「ウォッシュコート」は、処理されるガス流がそこを通過することを可能にするために十分に多孔である、ハニカム型基材または金網等の基材担体物質に適用される、触媒または他の物質の薄い接着層の、当該技術分野におけるその通常の意味を有する。
Claims (15)
- 内燃エンジン内で使用するための触媒物品であって、
基材上に形成される第1の触媒層であって、無セリア酸素貯蔵成分上に含浸されたパラジウムおよび耐熱金属酸化物上に含浸された白金を含む、第1の触媒層と、
前記第1の触媒層上に形成される第2の触媒層であって、酸素貯蔵成分上に含浸された白金およびジルコニア被覆またはイットリア被覆アルミナ上に含浸されたロジウムを含み、パラジウムを含有しない、第2の触媒層と、を備え、
前記触媒物品は、前記内燃エンジンからの排ガス中の窒素酸化物を還元するために有効である、触媒物品。 - 炭化水素、一酸化炭素、および窒素酸化物を含むエンジン排気を処理する方法であって、
前記排気を触媒物品と接触させることを含み、前記触媒物品は、1)基材上に被覆される第1の触媒層であって、無セリア酸素貯蔵成分上に含浸されたパラジウムおよび耐熱金属酸化物上に含浸された白金を含む、第1の触媒層と、
前記第1の触媒層上に形成される第2の触媒層であって、酸素貯蔵成分上に含浸された白金およびジルコニア被覆またはイットリア被覆アルミナ上に含浸されたロジウムを含み、パラジウムを含有しない、第2の触媒層と、を備え、
前記方法は、前記排気中の窒素酸化物を還元するために有効である、方法。 - 前記触媒物品は、基材上にエッチング被覆層をさらに備え、前記エッチング被覆層は、前記第1の触媒層の下にある、請求項1または2に記載の物品または方法。
- 前記触媒物品は、a)前記第1の触媒層に、プラセオジム添加ジルコニア上に含浸されたパラジウムおよびアルミナ上に含浸された白金と、b)前記第2の触媒層に、セリアジルコニア上に含浸された白金およびジルコニア被覆アルミナ上に含浸されたロジウムと、を含む、請求項1または2に記載の物品または方法。
- 前記触媒物品中の白金/パラジウム/ロジウムの比率は、それぞれ重量で0.5〜10/1〜80/0.5〜10である、請求項4に記載の物品または方法。
- 前記触媒物品は、合計30〜100g/ft3の白金族金属を含む、請求項5に記載の物品または方法。
- 前記触媒物品は、白金1〜90g/ft3、パラジウム1〜90g/ft3、およびロジウム1〜30g/ft3を含む、請求項6に記載の物品または方法。
- 前記触媒物品は、白金1〜2g/ft3、パラジウム40〜80g/ft3、およびロジウム2〜5g/ft3を含む、請求項7に記載の物品または方法。
- 前記触媒物品の前記第1の層は、ジルコニア−プラセオジム上に含浸されたパラジウムおよびアルミナ上に含浸された白金を含む、請求項1または2に記載の物品または方法。
- 前記触媒物品の前記第1の層は、前記アルミナ上に含浸されたパラジウムをさらに含む、請求項9に記載の物品または方法。
- 前記第2の触媒層の前記酸素貯蔵成分は、セリア含有酸素貯蔵成分である、請求項1または2に記載の物品または方法。
- パラジウムは、前記触媒物品中に、重量で白金の量の約20〜60倍およびロジウムの量の10〜30倍の量で存在する、請求項1または2に記載の物品または方法。
- 触媒物品を製造する方法であって、
基材上にスラリーであって、無セリア酸素貯蔵成分上に含浸されたパラジウムおよび耐熱金属酸化物上に含浸された白金を含むスラリーを沈澱させることによって、前記基材上に第1の層を形成することと、
前記第1の層を乾燥させることと、
前記第1の層上にスラリーであって、酸素貯蔵成分上に含浸された白金およびジルコニア被覆またはイットリア被覆アルミナ上に含浸されたロジウムを含み、パラジウムは含まないスラリーを沈澱させることによって、前記第1の層上に第2の層を形成することと、
前記第2の層を乾燥させることと、を含む、方法。 - 白金1〜2g/ft3、パラジウム20〜80g/ft3、およびロジウム2〜5g/ft3が、前記触媒物品上に形成される、請求項13に記載の方法。
- 白金、パラジウム、およびロジウムは、それぞれ重量で0.5〜10/1〜80/0.5〜10の比率で、前記触媒物品上に沈澱される、請求項13に記載の方法。
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US15405309P | 2009-02-20 | 2009-02-20 | |
US61/154,053 | 2009-02-20 | ||
US12/706,742 US10773209B2 (en) | 2009-02-20 | 2010-02-17 | Aging-resistant catalyst article for internal combustion engines |
US12/706,742 | 2010-02-17 | ||
PCT/US2010/024659 WO2010096612A2 (en) | 2009-02-20 | 2010-02-19 | Aging-resistant catalyst article for internal combustion engines |
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